 VIEW CASE STUDIES FOR THE PULP AND PAPER INDUSTRY
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For the highly-competitive pulp and paper industry, problems such as erosion, corrosion, abrasion, slippage, safety, leakage, replacement costs, insufficient pressure, unscheduled shutdowns, and stock contamination have a direct effect on the bottom line. The industry has recognized the numerous benefits from the utilization of Belzona's Advanced Polymers to solve these problems, and in the process keep plants running efficiently.
Belzona's pulp and paper industry customers range in size from small recycling operations to major, international conglomerates. Regardless of size or output, these customers continue to recognize the distinct cost saving advantages of using Belzona.
In the pulp and paper industry, Belzona's Advanced Polymeric Repair Systems can be used to repair and protect a wide variety of equipment and areas. The following applications represent only a fraction of what can be accomplished through the use of Belzona:
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| Belzona Can Restore and Protect Vital Pieces of Rotating Equipment |
The fan pump is the largest pump in the entire paper machine system. Unfortunately, these units are often overlooked, and neglect can lead to an unscheduled shutdown. Here, this four-year-old primary fan pump had suffered severe damage to the casing, cutwater, stuffing box, wear ring seats and even the entire rotor assembly.
The local Belzona Technical Consultant recommended the application of the Belzona Ceramic Metal System, which has given its owner over 10 years of uninterrupted service.
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| Minimizing Shutdown Time on Journal Rolls |
This is an excellent example of what happens to a pillow block bearing on a dryer journal when you have loss of lubrication or contamination. Conventional repairs would have cost the mill an enormous amount in terms of related downtime expense.
The Belzona repair was completed without removing the dryer journal shaft, thereby avoiding the costly disassembly. The entire repair, utilizing a Belzona in-place forming technique, was completed in 5 ½ hours. This Belzona application saved the mill over $US 100,000 and has been in service since 1996.
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| Providing Positive Grip for the Transfer of Solids |
Maintaining a positive grip system to assist the passage of raw materials as they travel through the production path of the mill helps to ensure that production is not interrupted.
Belzona's Polymeric Grip System is a versatile and efficient system that is easily applied to most surfaces without dismantling the equipment.
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| Virtually Eliminate the Possibility of Slip & Fall Accidents |
A safe working environment around fast moving pieces of equipment is extremely important. Oil, water, pulp and paper, leads to slip hazards.
Belzona's Safety Grip System was used to provide a safe, non-skid floor area that has proven resistant to mill traffic and process chemicals since 1987.
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| Repairing Expensive Paper Machine Rolls |
This couch roll's perforated shell -- containing one or two stationary high vacuum suction boxes for de-watering the sheet -- was damaged when a millwright's tool fell onto the web, causing a five-inch by three-inch indentation.
A Belzona 1000 Series Metallic Polymer was used to restore the couch roll's outside diameter. The tapered nylon plugs were used to form the proper diameter holes throughout the repair area. After grinding the surface to obtain the desired finish, these plugs were simply ejected from the inside of the roll.
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| Preventing Leakage of Vital Process Fluids |
Here, the gasketing material was leaking process oil at 110° F from the gearbox housing. An advanced Belzona Polymer was used to stop the leaking of oil from the sectional electric drive gearbox on a paper machine, thereby bringing the gearbox back online in a timely manner.
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| Prohibiting Steam Loss from Inside Dryer Rolls |
Prior to inspection, dryers are opened and drained. Visual inspection included an examination of the accessible areas of the internal and external surfaces of the shells, heads, bolts and trunion areas. Both the tending side and gear side head showed erosion at the shell interface. Circumferential groving was noted at 1/16th of an inch causing the leakage.
A Belzona 1300 Series System was used to rebuild the eroded areas. A state-of-the-art, ultra high-heat resistant Belzona Polymer was then used to give the repaired area wet heat resistance.
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| Arrest Loss of Stock from Packing Inside Knife Gate Valves |
Pulp and Paper mills usually replace knife gate valves often because of the abrasive environment in which they operate. Typical problems associated with pulp and paper service are corrosion, flashing, plugging, cavitation, noise, vibration and seat leakage.
A Belzona 2000 Series Elastomer was used to form a perfect seal within the stuffing box area. The Belzona material is comprised of 100% solids and will not shrink during cure. This Belzona application can be accomplished for a fraction of the conventional repair and has proven longevity, with customers reporting over three years of continuous service.
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| Keep Abrasive Wear from Interrupting Production |
Turbo separators suffer from severe abrasion from paper clips, staples, sand and other contaminants. Traditional, or conventional, repairs with replacement basalt tiles are time consuming and costly.
A Belzona Abrasion-resistant Polymer was used to create an even wearing surface, as well as to seal the worn porous grout commonly used around each of the tiles, for a fraction of the cost of basalt tile replacement.
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| Provides a Solution to Galvanic Corrosion in Evaporators |
Multiple effect evaporators suffer from the cycle of erosion and corrosion and ultimately accelerated deterioration from the galvanic effects. Here, 1/8-inch of metal was lost around the tubes, causing leaks.
A heat resistant Belzona polymer was used to rebuild the tube sheet face to eliminate the future possibility of further galvanic deterioration. Through the use of Belzona, the customer was able to avoid the re-tubing of these large units which can cost upwards of $US 800,000.
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| Stop Contamination and Increase Pulp Quality |
Storage of fiber stocks is necessary at appropriate points in the process to provide surge capacity and allow for interruptions in either supply or demand. These tile-lined chests are often spalled by white water chemical attack. The loose grout and concrete further contaminates the stock and causes concerns regarding pulp quality.
A non-porous Belzona 4000 Series Magma Polymer was used to restore the structure's integrity to better than new condition and will last for years to come.
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